Method of making a saw blade

ABSTRACT

A method of making a saw blade includes the step of providing a metallic blade body that defines a first side surface and a second side surface. The method further includes the step of providing the metallic material blade body with cutting teeth at an edge thereof. The method also includes the step of forming a plurality of discrete dimples on at least one of the side surfaces. The forming step includes the step of deforming the metallic blade body with pins on a die plate of a punch press so as to create a plurality of indentations in the side surface in which the dimples are formed.

[0001] This application is a continuation of co-pending U.S. applicationSer. No. 09/705,403, filed on Nov. 3, 2000, which in turn is acontinuation of co-pending U.S. application Ser. No. 09/136,676, filedon Aug. 19, 1998 (now U.S. Pat. No. 6,145,426), which in turn is acontinuation-in-part of U.S. application Ser. No. 08/730,398, filed onOct. 15, 1996 (now U.S. Pat. No. 5,802,947).

[0002] In Application Serial No. 730,398, of which, this application isa continuation-in-part dimpling of a circular saw blade to producediscrete ridges raised from the plane of the blade is described. Thedimpling process produces a cold working effect and the raised edgesprovide protection against overheating of the blade and scorching of theworkpiece when a planar side surface of the blade comes into contactwith a wall defining the kerf being produced by the teeth of the blade.The present application is directed to an extension of that principleand technique to linear saw blades and other applications for whichthose principles and techniques have utility.

[0003] Producing small, discrete, surfaces projecting from a planarsurface of jigsaw, hacksaw, or band saw blade, for example, iscounter-intuitive. Logically, clearance between the kerf produced by theteeth of the blade, and the body of the blade behind the teeth would bemaximized. However, it is a matter of common knowledge that the bodiesof jigsaw hacksaw or band saw blades frequently come into contact: withthe walls defining the kerf of a workpiece. The provision of low-profileprojections from such a blade reduces the surface of contact with thekerf wall.

BRIEF SUMMARY OF THE INVENTION

[0004] In accordance with this invention, generally stated, low-profile,discrete protrusions are provided on the blade behind the teeth orcutting edge of a tool, in the form of ridges on the perimeters ofindentations (concave dimples) or surfaces on the tops of domes (convexdimples). Preferably, the dimples are on both sides of the blade,although for some applications, protrusions on only one side may bedesired. The dimples can be concave on one side and convex on the other,the same punching process forming both, or concave or convex dimples canbe formed on both sides. Concave dimples with ridges at their perimetercan be formed in one or both sides, and convex dimples, without acorresponding concave dimple with a ridge, can be formed in one or bothsides. The dimples can be of any perimetric configuration, i.e.circular, teardrop shaped, star shaped, polygonal, or even irregularlyshaped, for example.

[0005] The dimples should be discrete, spaced from one another, andprojecting on the order of 0.005 inches from a planar surface of theblade, although the dimensions of the dimples and their projection fromthe surface can vary with the application to which they are put.

[0006] The arrangement of the dimples can also be varied. For example,on a jigsaw blade, the narrowness of the blade dictates that the dimplesbe small and in either a linear or slightly staggered configuration. Ina saber saw, band saw or hack saw, the width of the blade will permit awider variety of pattern, or random distribution of dimples. In a holesaw, pruning saw, hand saw, or bow saw, for example, the patterns can besomewhat more open because of the greater width of the blade.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0007] In the drawings, FIG. 1 is a view in side elevation of a sabersaw blade in which, by way of illustration, dimples of various types andsizes are shown;

[0008]FIG. 2 is a fragmentary sectional view of a blade showing concavedimples formed directly opposite one another on opposite flat sidesurfaces of the blade, each with a ridge on its perimeter;

[0009]FIG. 3 is a fragmentary sectional view of a blade showing concavedimples formed on opposite sides but staggered with respect to oneanother, each with a ridge on its perimeter;

[0010]FIG. 4 is a fragmentary sectional view taken along the line 4-4 ofFIG. 1;

[0011]FIG. 5 is a fragmentary sectional view of a blade in which ridgedconcave dimples are provided on one side, and convex dimples, on theother side;

[0012]FIG. 6 is a fragmentary sectional view of a diamond shaped concavedimple taken along the line 6-6 of FIG. 1;

[0013]FIG. 7 is a view in side elevation of a jigsaw blade in which arow of dimples has been formed;

[0014]FIG. 8 is a view in side elevation of a small saber saw blade inwhich dimples of various sizes and configurations have been formed;

[0015]FIG. 9 is a bottom edge view of the saw blade shown in FIG. 7,showing the staggered teeth;

[0016]FIG. 10 is fragmentary view in side elevation of a hack or bandsaw blade with dimples of various sizes and shapes in a random pattern;

[0017]FIG. 11 is a view in perspective of a hole saw in which dimpleshave been formed; and;

[0018]FIG. 12 is a top plan view of a strip used to form the blade ofthe hole saw of FIG. 11, before it is curled and welded.

[0019] Corresponding reference numerals will be used throughout theseveral figures of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0020] The following detailed description illustrates the invention byway of example and not by way of limitation. This description willclearly enable one skilled in the art to make and use the invention, anddescribes several embodiments, adaptations, variations, alternatives anduses of the invention, including what we presently believe is the bestmode of carrying out the invention.

[0021] Referring to FIG. 1 of the drawings, reference numeral 1indicates a saber saw blade with a flat sided body 2 and teeth 3 along anarrow edge of the body. Merely by way of illustration, the body of theblade 1 is shown as having formed in it a number of different types ofdimples, although normally only one type of dimple would be used on anyone blade, spread along the length of the blade. FIG. 2 is anillustrative example of some of the dimples in the blade of FIG. 1,wherein concave dimples 4 with ridges 5 along their perimeters are shownas being positioned directly opposite one another on two flat sides ofthe blade In FIG. 3, the dimples are shown as being staggered withrespect to one another on opposite sides of the blade. FIG. 4, which isa fragmentary sectional view taken along the line 4-4, illustratesconcave dimples 7 without ridges, with complementary convex dimples 8,with an outermost smooth domed surface 9, alternately on one side andthe other. FIG. 5 illustrates a concave dimple 4, with a ridge 5, on oneside and a complementary convex dimple 8, with an outermost smoothsurface 9. FIG. 6 is a fragmentary sectional view taken along the line6-6 of FIG. 1, showing a diamond shaped concave dimple 14 with a ridge15 at its perimeter. Reference numeral 17 indicates teardrop shapeddimples, which can be either concave or convex.

[0022] Referring to FIG. 7, reference numeral 20 indicates a jig sawblade, with a body 21 and teeth 22. Dimples 23 in the body 21 can be ofthe types shown in FIGS. 2 and 3 or of the types shown in FIGS. 4 and 5.Because the body 21 is so narrow, the dimples 23 are shown as arrangedin a straight line.

[0023] In FIG. 8, a different type of saber saw is illustrated, in whichdimples of various shapes and sizes are arranged in a more or lessrandom pattern.

[0024]FIG. 9 illustrates the teeth of saws provided with dimples, and inparticular the jig saw blade of FIG. 7. The teeth are staggered in sucha way as to produce a kerf at least slightly wider than the protrusionof the dimples, so that normally the protrusions, whether they be convexdomes or ridges, do not engage the walls defining the kerf.

[0025]FIG. 10 illustrates a band or hack saw blade 24, which, merely forpurposes of illustration, is shown with dimples 25 of various sizes. Thedimples on the left part of the blade are shown as arranged in a regularpattern, which would normally be the case. The dimples on the right sideof the illustration are shown as of various sizes and shapes, arrangedin a more or less random pattern, merely to illustrate that possibility.

[0026]FIG. 11 shows a hole saw 26 with a circular top 30 and acylindrical blade 28 with a body 29 along a free edge of which teeth 31extend. Dimples 32, in the embodiment shown, are convex on the exteriorsurface of the blade body 29. Although they are not illustrated, thedimples 32 can have counterpart concave dimples on the inner surface ofthe cylindrical blade body, which can be of the type shown in FIG. 5, toprovide protrusions on the inner surface, as well as on the outer, orthe hole saw can be provided with any of the other types of dimples thathave been illustrated or described.

[0027]FIG. 12 illustrates the blade 28 of the hole saw 26 as it is madebefore it is curled and welded at its free ends to form a cylinder asindicated in FIG. 11. This simplifies the formation of the dimples 32.

[0028] It will be apparent to those skilled in the art that the dimplingcan be applied to a wide variety of tools beyond those specificallyillustrated, as has been indicated heretofore. In a toothless blade,particularly a food slicing blade, the dimples are preferably madeentirely convex, or, if complementary concave dimples are formed in theprocess of producing the convex dimples, at least making thecomplementary concave dimples without ridges, to make cleaning easier.Preferably, in every case, the dimples are formed with a punch press,which gives the benefit of the cold-working described in applicationserial number 730,398. Pins, set in a die plate, can be used to form theconcave dimples, and if convex dimples are to be formed, to form theconcave dimples on one side and complementary convex dimples on theother at the same time. It is possible to form the dimples in a rollingprocess either in the course of manufacturing stock of which the bladesare made, or subsequently. The dimples can be produced on only one sideof a blade that is expected to be used in such a way that only one sideis likely to come into contact with a kerf wall. Numerous othervariations in the tools of this invention and the method of theirmanufacture within the scope of the appended claims will become apparentto those skilled in the art in the light of the foregoing disclosure.

[0029] As various changes could be made in the above constructionswithout departing from the scope of the invention, it is intended thatall matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

What is claimed is:
 1. A method of making a saw blade, comprising thesteps of: providing a metallic blade body that defines a first sidesurface and a second side surface, providing said metallic blade bodywith cutting teeth at an edge thereof; and forming a plurality ofdiscrete dimples on at least one of said side surfaces, said formingstep including the step of deforming said metallic blade body with pinson a die plate of a punch press so as to create a plurality ofindentations in said side surface in which said dimples are formed. 2.The method of claim 1, further comprising the step of configuring saidmetallic blade body to form any one of the following group: a jig sawblade, a saber saw blade, a hack saw blade, a bow saw blade, a hand sawblade, a bone saw blade, a pruning saw blade, a keyhole saw blade, amiter saw blade, and a band saw blade.
 3. The method of claim 1, whereinsaid forming step includes the step of configuring each of saidplurality of dimples to define a perimeter which is spaced apart fromall edges of said metallic blade body.
 4. The method of claim 3, whereinsaid forming step further includes the step of configuring each of saidplurality of dimples to include a ridge which is located at saidperimeter.
 5. The method of claim 4, wherein said forming step furtherincludes the step of configuring at least a portion of said ridge toextend above said side surface of said metallic blade body in which saiddimples are formed.
 6. A method of making a saw blade, comprising thesteps of: providing a blade body which defines a side surface; providingsaid blade body with cutting teeth; and deforming said blade body withpins on a die plate of a punch press so as to create a plurality ofdimples in said side surface.
 7. The method of claim 6, furthercomprising the step of configuring said blade body to form any one ofthe following group: a jig saw blade, a saber saw blade, a hack sawblade, a bow saw blade, a hand saw blade, a bone saw blade, a pruningsaw blade, a keyhole saw blade, a miter saw blade, and a band saw blade.8. The method of claim 6, wherein said deforming step includes the stepof configuring each of said plurality of dimples to define a perimeterwhich is spaced apart from all edges of said blade body.
 9. The methodof claim 8, wherein said deforming step further includes the step ofconfiguring each of said plurality of dimples to include a ridge whichis located at said perimeter.
 10. The method of claim 9, wherein saiddeforming step further includes the step of configuring at least aportion of said ridge to extend above said side surface of said bladebody.
 11. The method of claim 6, wherein said blade body is made ofmetal.
 12. A method of making a saw blade, comprising the steps of:providing a metallic blade body which defines a first side surface and asecond side surface; and providing said metallic blade body with cuttingteeth at an edge thereof; and deforming both said first side surface andsaid second side surface with pins on a die plate of a punch press so asto create a plurality of dimples in each said first side surface andsaid second side surface.
 13. The method of claim 12, further comprisingthe step of configuring said metallic blade body to form any one of thefollowing group: a jig saw blade, a saber saw blade, a hack saw blade, abow saw blade, a hand saw blade, a bone saw blade, a pruning saw blade,a keyhole saw blade, a miter saw blade, and a band saw blade.
 14. Themethod of claim 12, wherein said deforming step includes the step ofconfiguring each of said plurality of dimples to define a perimeterwhich is spaced apart from all edges of said metallic blade body. 15.The method of claim 14, wherein said deforming step further includes thestep of configuring each of said plurality of dimples to include a ridgewhich is located at said perimeter.
 16. The method of claim 15, whereinsaid deforming step further includes the step of configuring at least aportion of said ridge to extend above said side surface of said metallicblade body.